Issue with nearly new car

I have owned a 2011 Volvo V50 D2 DRIVe 1.6 bought as a demonstrator in May 2011 with only 11 miles on the clock at the time of purchase.

After approximately 2000 miles the gearbox developed a clunk when changing up and down between 2nd and 3rd and 3rd and 4th gear.

When it had the 3000 mile check by Mill Volvo of Stockton on Tees I was advised that they acknowledged the noise but couldn't see or find anything wrong.

In the meantime I have observed that there are lots of owners on the Volvo Owners Forum complaining of the same issue, and that Volvo apparently acknoweledge the problem but do not have a fix.

Yesterday the car was again inspected by Mill Volvo at 6500 miles,they consulted Volvo's technical library which acknowledges that the noise is the Dual Mass Fly Wheel and that it is not a fault as such, just a characteristic of this model.

They specifically instructed dealers not to change any parts. They said that the part would be fully covered by the 3 year warranty.

I am unhappy with this reponse as I intend to keep the car for a good few years, and would not expect this noise on a Volvo after high miles, let alone from almost new. I have previously run 2.0D models as company cars and both had no such issues with the gearbox.

I intend on speaking to Volvo's customer service people but would appreciate any insight you could provide in terms of what I should/could expect in terms of action from them.

Asked on 6 January 2012 by Acko

Answered by Honest John
I have the same drivetrain in a Mazda 5 1.6D and no trouble, maybe because of a lower final drive ratio. Could be that raising this too high in the Volvo has caused the problem. The clunk very probably is the dual mass flywheel and these typically have a life of anything between 30,000 miles and 200,000 miles.
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